Dodge Durango (DN). Manual — part 107

(3) Install

annulus

gear

on

output

shaft,

if

removed. Then install annulus gear retaining snap
ring (Fig. 276).

(4) Align and install clutch drum on annulus gear

(Fig. 277). Be sure drum is engaged in annulus gear
lugs.

(5) Install clutch drum outer retaining ring (Fig.

277).

(6) Slide clutch drum forward and install inner

retaining ring (Fig. 278).

(7) Install rear bearing and snap ring on output

shaft (Fig. 279). Be sure locating ring groove in bear-
ing is toward rear.

(8) Install overrunning clutch on hub (Fig. 280).

Note that clutch only fits one way. Shoulder on
clutch should seat in small recess at edge of
hub.

(9) Install thrust bearing on overrunning clutch

hub. Use generous amount of petroleum jelly to hold
bearing in place for installation. Bearing fits one
way only. Be sure bearing is seated squarely
against hub. Reinstall bearing if it does not
seat squarely.

(10) Install overrunning clutch in output shaft

(Fig. 281). Insert snap ring pliers in hub splines.
Expand pliers to grip hub. Then install assembly
with counterclockwise, twisting motion.

(11) Install planetary gear in annulus gear (Fig.

282). Be sure planetary pinions are fully seated
in annulus gear before proceeding.

(12) Coat planetary thrust bearing and bearing

contact surface of spring plate with generous amount

Fig. 276 Annulus Gear Installation

1 – SNAP RING
2 – OUTPUT SHAFT FRONT BEARING
3 – ANNULUS GEAR

Fig. 277 Clutch Drum And Outer Retaining Ring

Installation

1 – ANNULUS GEAR
2 – OUTER SNAP RING
3 – CLUTCH DRUM

Fig. 278 Clutch Drum Inner Retaining Ring

Installation

1 – ANNULUS GEAR
2 – INNER SNAP RING
3 – CLUTCH DRUM

Fig. 279 Rear Bearing And Snap Ring Installation

1 – REAR BEARING
2 – SNAP RING

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DISASSEMBLY AND ASSEMBLY (Continued)

of petroleum jelly. This will help hold bearing in
place during installation.

(13) Install planetary thrust bearing on sun gear

(Fig. 283). Slide bearing onto gear and seat it against
spring plate as shown. Bearing fits one way only.
If it does not seat squarely against spring plate,
remove and reposition bearing.

(14) Install assembled sun gear, spring plate and

thrust bearing (Fig. 284). Be sure sun gear and
thrust bearing are fully seated before proceeding.

(15) Mount assembled output shaft, annulus gear,

and clutch drum in shop press. Direct clutch spring,
hub and clutch pack are easier to install with assem-
bly mounted in press.

Fig. 280 Assembling Overrunning Clutch And Hub

1 – CLUTCH HUB
2 – OVERRUNNING CLUTCH

Fig. 281 Overrunning Clutch Installation

1 – CLUTCH DRUM
2 – OVERRUNNING CLUTCH ASSEMBLY
3 – EXPANDING-TYPE SNAP RING PLIERS
4 – CLUTCH DRUM
5 – ANNULUS GEAR
6 – OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT

SHAFT

Fig. 282 Planetary Gear Installation

1 – PLANETARY GEAR
2 – ANNULUS GEAR

Fig. 283 Planetary Thrust Bearing Installation

1 – SPRING PLATE
2 – PLANETARY THRUST BEARING
3 – SUN GEAR

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DISASSEMBLY AND ASSEMBLY (Continued)

(16) Align splines in hubs of planetary gear and

overrunning clutch with Alignment tool 6227-2 (Fig.
285). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.

(17) Install direct clutch spring (Fig. 286). Be sure

spring is properly seated on spring plate.

(18) Assemble and install direct clutch pack on

hub as follows:

(a) Assemble clutch pack components (Fig. 287).
(b) Install direct clutch reaction plate on clutch

hub first. Note that one side of reaction plate
is counterbored. Be sure this side faces rear-
ward. Splines at rear of hub are raised
slightly. Counterbore in plate fits over raised
splines. Plate should be flush with this end of
hub (Fig. 288).

(c) Install first clutch disc followed by a steel

plate until all discs and plates have been installed.

(d) Install pressure plate. This is last clutch

pack item to be installed. Be sure plate is
installed with shoulder side facing upward
(Fig. 289).
(19) Install clutch hub and clutch pack on direct

clutch spring (Fig. 290). Be sure hub is started on
sun gear splines before proceeding.

Fig. 284 Sun Gear Installation

1 – SUN GEAR AND SPRING PLATE ASSEMBLY

Fig. 285 Alignment Tool Installation

1 – SPECIAL TOOL 6227–2
2 – PRESS PLATES
3 – ASSEMBLED DRUM AND ANNULUS GEAR
4 – SUN GEAR

Fig. 286 Direct Clutch Spring Installation

1 – SPECIAL TOOL 6227–2
2 – DIRECT CLUTCH SPRING
3 – CLUTCH HUB
4 – PRESS PLATES

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Fig. 287 46RE Direct Clutch Pack Components

1 – CLUTCH DISCS (8)
2 – PRESSURE PLATE

3 – CLUTCH PLATES (7)
4 – REACTION PLATE

Fig. 288 Correct Position Of Direct Clutch Reaction

Plate

1 – REACTION PLATE COUNTERBORE
2 – DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF

HUB)

3 – CLUTCH HUB

Fig. 289 Correct Position Of Direct Clutch Pressure

Plate

1 – DIRECT CLUTCH PRESSURE PLATE
2 – CLUTCH PACK
3 – BE SURE SHOULDER SIDE OF PLATE FACES UPWARD

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DISASSEMBLY AND ASSEMBLY (Continued)